81 suzuki gs 250 rebuild

[ghostwriter247]

This is kind of my introduction and rebuild thread. Havent been here since i owned a gs 500 long ago btu have been lurking for a couple months.

A chance conversation at work resulted in a free 250 that he just wanted out of the garage. It didnt run, and had been stripped. the head pipes had been cut right in front of the h box and wrapped. It had been modified to look like an old flat tracker.

http://www.creativeexposuremultimedi...c0ad#h65d4c0ad

Ive done quite a bit of work already so will break the posts up a bit so its not one really long post.

So i got her home and didnt quite know where to start, but usually i just start tearing into things to clean it up so i did. The first order of business was a turning the crank to see if she was seized but she wasnt yay so a new battery and a compression test. I couldnt get one til the next day, so i started breaking her down to this.

http://www.creativeexposuremultimedi...c0ad#h69ca04a4

The compression test did not turn out so well. 90 in the left cylinder and 150 in the right. some oil in the cylinder brought it right up to 150 again so a rebuild was in order.

[ghostwriter247]

k sorry guys but im having problems getting the photos up loaded so im stuck with urls i guess

[ghostwriter247]

She sat for a number of weeks while i had a new baby and got sidetracked cleaning up my stepsons cx500 he just got. But i did manage to get back to it and stripped the carbs down. not too bad but in need of a cleaning. So i pulled the engine and all the other frame pieces and wound up with this

http://www.creativeexposuremultimedi...c0ad#h6ea03672


Here is another better shot of the stripped tail and tank. pretty bare bones flat seat

http://www.creativeexposuremultimedia.com/josh/h65d4c0ad#h6b4b3dbc

I spent the better part of three days pulling the frame apart and sandblasting, priming and painting. Definitely glad i did that. the stemhead bearings fell apart in my hands. here are some pics of the frame and pieces hanging and painted

All blasted and primed

http://www.creativeexposuremultimedi...c0ad#h63336f97

http://www.creativeexposuremultimedi...c0ad#h66dd8d5a

and painted.

http://www.creativeexposuremultimedi...c0ad#h6fad14a7

I repainted every frame piece swingarm etc in a semi gloss black and turned out real nice.

On the the engine late last night. I scrubbed her as best i could and got 30 years of gunk off of her. and started the tear down. it was slow going as i had never torn down an engine this far but had alot of theory. Lots of hidden screws keeping things together. My plan was to not crack the main case or the oil pan cover. but pull the rest and renew rings and gaskets. That didnt work out so well as when i was pulling the jugs i heard that wonderful tink tink tink as one of the dowels dropped into the case.

[ghostwriter247]

so i pulled the side covers and oil cover as well as turned her upside down but no joy on the dowel coming back out. Luckily i dropped the oil pan and it dropped out after some shaking...Whew!

http://www.creativeexposuremultimedi...c0ad#h635f7484

and the case

http://www.creativeexposuremultimedi...c0ad#h6d3dce58

And she is all torn down too.

[pete]

Hey mate, welcome! Looking forward to following along, unfortunately none of those links are working for me. I'm not on Facebook which could be the reason...

Try a Photobucket account, I find that's the easiest way.

[ghostwriter247]

Im gonna get them uploaded to my photography site. Im actually a pro photographer so ill create a gallery on that site and post a link here in a minute. stay tuned!

[ghostwriter247]

updated the photo links and anyone should be able to see those, although hopefully not my clients since i took them with an iPhone!

[ghostwriter247]

Got the carbs taken apart as well but pics of those later. Not too bad so im gonna get an ultrasonic cleaner to make sure they are scrubbed out.